Electrostatic powder coating apparatus

ABSTRACT

An electrostatic powder coating apparatus for coating the surfaces of articles with pulverulent materials having an ionization member which serves as both an improved charging means and a pattern forming deflecting means including a probe portion positioned immediately to the rear of a deflecting member and a probe portion extending past a forward-most surface of the deflecting member, with said portions of the probe being maintained at an electrical potential substantially different than that of the article to be coated.

United States Patent Sherman et a1.

June 6, 1972 FOREIGN PATENTS OR APPLICATIONS 1,548,327 10/1968 France ..239/l5 2 l t Rich d M. She N th '11 M' h.; [7 nven ors M gz W e Primary Examiner-M. Henson Wood, Jr. g Assistant Examiner-Thomas C. Culp, Jr. [73] Assignee: Graco Inc., Minneapolis, Minn. Attorney-Frederick E. Lange, William C. Babcock and David N, Fronek [22] Filedz, ,Feb, 16, 1971 21 App1.No.: 115,685 [57] ABSTRACT I An electrostatic powder coating apparatus for coating the surfaces of articles with pulverulent materials having an ioniza- [52] U.S. Cl. ..239/15, 317/3 on member which Serves as both an improved charging [51] -Int.Cl ..B05b 5/00 means and a pattern f i d fl ti means induding a Field of Seamh 3 probe portion positioned immediately to the rear of a deflecting member and a probe portion extending past a forward- [56] Referen e Cited most surface of the deflecting member, with said portions of the probe being maintained at an electrical potential substan- UNITED STATES PATENTS tially different than that of the article to be coated.

3,575,344 4/1971 Angelico ..239/3 X 24 Claims, 3 Drawing figures 3 19 POM 2 4 20 v sol/er:

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ELECTROSTATIC POWDER COATING APPARATUS BACKGROUND OF THE INVENTION The present invention relates generally to an electrostatic powder coating apparatus for electrostatically coating pulverulent materials onto an article to be coated. More specifically, the present invention relates to an improved electrostatic powder coating apparatus having an improved nozzle portion for charging the pulverulent materials as they pass through and exit from a material passage of the spray gun and for forming the pulverulent materials into a desired spray pattern for maximumdeposition and wrap-around of the particles onto the article to be coated. With the present invention, the desired deposition and wrap-around is attained with a voltage substantially less than that necessary in the past.

Although the concept of electrostatic coating is generally fairly well understood, especially the electrostatic coating of liquid materials, the details of the concept of electrostatic deposition of pulverulent materials requires further refinement. In other'words, the general problems and difficulties dealing with the electrostatic deposition of pulverulent materials are known, but their solutions in terms of designing a spray gun to operate at optimum conditions is unknown. For example, it is well known in the field of electrostatic powder coating that an operable electrostatic powder coating apparatus must include a means for dispersing the pulverulent materials by a compressed air current or other means'so that the particles can be deposited onto the article to be coated as individual particles, a means for imparting a charge to the individual particles either by causing the particles to directly contact an electrically conductive element containing such charges or by causing the particles to pass through an electrostatic field set up between electrodes maintained at two different potentials, and a means for deflecting and forming the pulverulent materials into a desired spray pattern. One of the specific shortcomings of the prior spray gunslwas the inefficient use of the high voltage supplied to the ionizing member. Often the high voltage potential of the prior art ionizing members was not efficiently used because of the stray or unintentional capacitance between the ionizing electrode and grounded objects other than the article to be coated.

SUMMARY OF THE INVENTION In contrast to the electrostatic powder coating apparatus of the past, the present invention provides an improved spray gun having an improved nozzle assembly including an ionization member adapted to be quickly and easily removed from the forward portion. of the spray 'gun for cleaning and then reinserted and which serves both as an improved charging means and a pattern forming deflector. The specific structure on the improved ionization member includes a probe extending from one end of the ionization member to the other, a body member having a plurality of fins equally spaced and radially extending from the rearward end of the probe for retaining the ionization member within the spray gun, a contact ring member mounted on the fins for electrically connecting a high voltage. source with the probe, and a deflecting member positioned at the forward end of the probe in a posi-.

tion such that a portion of the probe extends past an exterior surface of the deflecting member such that the deflecting member is spaced forwardly from the body member. When the high voltage source is actuated, the probe is elevated to a potential substantially greater than the potential of the article to be coated and an electrostatic field is set up between the article to be coated and each of the portion of the probe extending through the deflecting member and the portion of the probe locatedv between the deflecting member and the cone body. It has been found that a structure of this sort affords the desired deposition and wrap-around of the pulverulent materials onto the article to be coated with a significant reduction in stray or unintentional capacitance between these probe portions and grounded objects other than the article to be coated and thereby requiring a much smaller voltage than spray guns of the past.

Accordingly, it is an object of the present invention to provide an electrostatic powder coating apparatus having an ionization member which serves both to charge the pulverulent materials to be coated and as a deflector to form the pulverulent materials into a desired spray pattern.

Another object of the present invention is to provide an electrostatic powder coating apparatus having an electrically non-conductive cylindrical sleeve telescopically mounted for axial movement along the end of the gun barrel so that one end of the sleeve extends to a plurality of positions past the end of the gun barrel for varying the spray pattern of the pulverulent materials being discharged from the gun.

Another object of the present invention is to provide an electrostatic powder coating apparatus in which the ionization member which serves as both a charging means and a deflecting means is easily removable from the spray gun to facilitate easy cleaning of the member when it is desired to use the apparatus to coat a material having a different characteristic.

A further object of the present invention is to provide an electrostatic powder coating apparatus having an ionization member with which the same deposition of pulverulent materials and the same wrap-around of pulverulent materials can be attained with a substantially lower voltage than electrostatic guns of the past.

These and other objects of the present invention will become apparent by referring to the preferred embodiment, the drawings, and the appended claims.

.DESCRIPTION OF THE DRAWINGS FIG. 1 is an elevated view partially in section showing the improved spray gun of the present invention.

FIG. 2 is a detailed exploded perspective view partially in section of the nozzle portion of the spray gun.

FIG. 3 is a sectional view of FIG. 1 as viewed from line 3-3.

DESCRIPTION OF THE PREFERRED EMBODIMENT As shown in FIG. 1 of the preferred embodiment, the electrostatic powder coating gun 10 of the present invention includes generally a barrel portion 11, a nozzle portion 15 located near the front of the barrel portion 11, a handle 12, a trigger 14 and a means located near the rear portion of the gun 10 for supplying high voltage and pulverulent materials to the gun 10.

More specifically, the barrel portion 11 of the gun 10 encloses a generally cylindrical material passage 18 extending longitudinally throughthe spray gun 10and through the entire barrel portion 1 l, and a generally cylindrical high voltage chamber 19 extending longitudinally through part of the barrel portion 11. In the preferred embodiment, substantially all of the barrel portion 11, and especially those portions of the barrel 11 which enclose the material passage 18 and high voltage chamber 19, are constructed from a molded polyethylene which is electrically non-conductive.

The high voltage chamber 19 is separated from the material passage 18 by a molded polyethylene wall 20 and is disposed within the barrel 1 l in a position which is substantially parallel to the passage 18. The chamber 19 extends forwardly through the barrel ,11 to a forward barrel portion 21 and rearwardly through the barrel 11 to and through a metal rear portion of the gun 22. At its front end, the chamber 19 houses a 150- megohm resistor 24, the rear end of which is electrically connected to a high voltage cable 25 housed in the rearward portion of the chamber 19. The resistor 24 and the cable 25 are electrically connected by a stress relief cap 26 which includes a compression spring 28 biasing the resistor 24 toward the forward end of the chamber 19, The rearward portion of the high a contact or ring member 32 disposed within the material passage 18 and which will be more fully described below. Directly above the set screw 31 is a plug 34 which is threadedly received by a portion of the barrel and which can readily be removed for adjustment or removal of the set screw 31.

The nozzle portion located near the forward end of the barrel 11 generally includes a pattern control sleeve or cylindrical member 36 telescopically mounted over a portion of the forward end of the barrel 11 and adapted for axially sliding movement along the forward portion of the barrel 11. The sleeve 36, constructed of an electrically non-conductive material such as a linear synthetic polyamide, commonly sold under the trademark Nylon, includes a relatively cylindrical interior surface 38 substantially conforming in diameter to the exterior surface of the forward end of the barrel 11, a forward end portion 39 which, when the sleeve 36 is moved to an extended position, is disposed at a position spaced forwardly from the forward end of the passage 18, a rearward end portion 40, and a set screw 41 extending through the body of the sleeve 36 for a limited distance to engage the longitudinal channel 42 which is formed in a portion of the exterior surface of the barrel 11. As shown by the broken line 33, the sleeve 36 can be moved to a plurality of extended positions in which the forward end 39 is forwardly spaced from the forward end of the passage 18. When in a retracted position, the forward end 39 does not extend forward of the forward end of said passage 18. When the screw 41 engages the channel 42, the axial movement of the sleeve 36 is limited as a result of the screw 41 engaging the shoulder portions of the channel 42. In this manner, the sleeve 36 cannot inadvertently be moved to an extent that the sleeve is removed from the barrel 11. Also, the screw 41 can be tightened against the inner surface of the channel 42 when the sleeve 36 is in a desired position to thereby retain the sleeve 36 in that position.

As also shown in FIG. 1, the forwardmost interior surface of the passage 18 is curved or flared outwardly, This flaring, in combination with the axially movable sleeve 36 and the deflecting member 44, which will be described in more detail below, causes the pulverulent materials passing through the passage 18 to be formed into a desired spray pattern.

Referring now to FIG. 2, an elongated ionization member 37 disposed within the passage 18 includes a probe or electrode 45, a deflecting member 44, a body member 46 and a ring member 32. The probe 45 extends the entire length of the ionization member 37. At its rearward end 48, the probe 45 is electrically connected to the ring member 32 by a conducting wire 49. At its forwardmost end, the probe 45 passes through the deflecting member 44 and extends past the concave surface 59 of the deflector 44. The portion of the probe 45 extending past the surface 59 serves an an ionization point or needle 50 causing an electrostatic field to be set up between the point 50 and the article to be coated 13 when the point 50 and the article 13 are maintained at substantially different electrical potentials.

The generally cylindrical body member 46 surrounds a substantial portion of the probe 45 and extends from the rearward end 48 of the probe 45 to a point 51 near the forward end of the probe 45. In the preferred embodiment, the location of the point 51 is substantially even with the forward end of the passage l8'when the member 37 is operatively disposed within the passage 18.

A plurality of fins 52 integrallyformed with the rearward portion of the body member 46 are spaced about the circumference of the member 46 and extend upwardly therefrom such that the diameter of the exterior fin surfaces is slightly larger than the interior diameter of the material passage 18 so that the ionization member 37 may be retained within the passage 18. As better seen in FIG. 3, the plurality of fins 52 are equally spaced about the circumference of the body member 46 and extend radially outwardly therefrom.

Referring now to both FIGS. 2 and 3, a ring member 32 is mounted to a portion of the fins 52 at a position which is spaced forwardly from the rearward end 48 of the probe. Referring specifically to FIG. 3, the mounting of the ring in this manner provides a plurality of passages 54 through which the pulverulent materials may pass as they are conveyed through the passage 18.

The ring member 32 is constructed of an electrically conductive material and is electrically connected to the resistor 24 (FIG. 1) by the set screw 31. When the ionization member 37 is inserted into the forward end of the passage 18, the ring 32 engages the set screw 31, thereby electrically connecting the ring 32 with the screw 31, and also preventing further inward movement of the ionization member 37. The member 37 is then retained in this position by the plurality of fins 52 which are force fitted against the interior surface of the passage 18. Because the member 37 is secured within the passage 18 due to the flexible and somewhat resilient nature of the fins 52, the member 37 can easily be removed, cleaned and replaced when such cleaning is desired. This is often the case when the gun or the system is changed from spraying a pulverulent material having one characteristic to a pulverulent material having another.

The deflecting member 44 through which the forward portion of the probe 45 passes is generally conical in shape and includes a cylindrical surface 56, a tapered or conical surface 55 extending from the surface 56 and tapered inwardly toward the body member 46, a tapered surface 58 extending from a cylindrical portion 57 of the member 44 inwardly away from the body member 46, a shoulder portion 60 connecting the surface 56 with the surface 58, and a concave surface 59 which is perpendicular to the longitudinal axis of the probe 45 and which is the forwardmost surface of the deflector 44. The body member 46, the fins 52 and the deflecting member 44 are all constructed of non-conductive material such as a linear synthetic polyamide commonly sold under the trademark Nylon.

As best shown in FIG. 2, the tapered surface 55 tapers inwardly toward the body member 46 and terminates at a point which is spaced from the forwardmost point 51 of the body 46. This provides for a portion 61 of the electrically conductive probe 45 to be directly exposed to the pulverulent materials being discharged from the end of the material passage 18. It is believed that an electrostatic field is set up between the portion 61 and the grounded article 13 to thereby supercharge or precharge the pulverulent materials being emitted from the passage 18, thereby causing greater wrap-around and better deposition of the particles onto the article 13 with a substantially lower voltage.

As shown in FIG. 2, the forwardmost portion of the probe 45, the ionization point 50, extends for a distance past the' concave surface 59. A difference in electrical potential between the point 50 and the article 13 causes an electrostatic field to be formed between the point 50 and the grounded article 13 to thereby additionally charge the pulverulent materials emitted from the material passage 18 and direct those charged particles toward and onto the article 13. It should be noted that in the preferred embodiment the forwardmost point of the needle 50 does not extend past the edge formed between the tapered surface 58 and the concave surface 59, but rather is shielded within the concave portion formed by the surface 59. This shielding prevents pulverulent materials which have been precharged by the portion 61 from being repelled by the needle 50 which contains charges of identical polarity to the charges then carried by the pulverulent particles and also limits undesired contact with the point 50. It is believed that this shielding results in a more efficient system which can provide the same wrap-around and same deposition with a much lower voltage.

Referring again to FIG. 1, the rearward portion of the gun 10 of the present invention can be seen as including a metal portion 22, a handle 12 extending downwardly from the rear portion 22, a trigger 14 pivotally connected to the gun at the pivot 62, and a hook 64 by which the gun 10 can be hung when it is not in use. Extending through the material passage 18 is a relatively rigid, electrically non-conductive tube 65 for conveying pulverulent materials through the passage 18. As shown in the preferred embodiment, the tube 65 extends through a substantial portion of the passage 18 with its forward end 66 terminating at a point which is spaced rearwardly of the set screw 31. The rearward end 68 of the tube 65 includes a portion containing a plurality of circumferential ribs 69 which are adapted for attachment of the end 68 to a flexible tube 70 of the type normally used for transporting pulverulent materials in an electrostatic spraying system.

The tube 65, although relatively rigid when compared to the hose 70, is not so rigid that it cannot be bent slightly, and is generally cylindrical having an external diameter slightly smaller than the intemaldiameter of the material passage 18. With this construction, the tube 65, with the flexible hose 70 attached to its rearward end, can be easily inserted into and removed from the material passage 18 when such insertion or removal is desired. When the tube 65 has been inserted into the passage 18, it is held tightly in place by the fitting 71 which contains internal threads for engagement with a corresponding externally threaded member 72 integrally formed with the gun body 10. A set screw 67 may also be contained in the gun wall and adapted to aid in retaining the tube 65 within the passage 18.

The specific structure of the embodiment shown in FIG. 1, due to the fact that the tube 65 and hose 70 are easily and quickly removable from the gun, allows several such tubes and hoses, each associated with'a pulverulent material with a different characteristic, to be selectively used with the gun. This permits the spray gun of the present invention to be changed from the spraying of a pulverulent material having one characteristic to the spraying of a pulverulent material having another with little inconvenience to the operator. This feature will be discussed in more detail below.

Also shown in FIG. 1 is the means 74 for selectively actuating both the powder supply 75, which includes a plurality of powder supply units, and the high voltage source 30. This means includes an on-off" control switch 76'which, when in the on" position, electrically connects a ground terminal witha male jack 80. This ground terminal (not shown) enters the gun together with the high-voltage cable. When the switch is in the off" position, the aforementioned ground terminal and the'male jack 80 are not electrically connected. The control switch 76, in turn, is controlled by movement of the trigger 14 toward or away from the handle 12 respectively. When the trigger 14 is moved toward the handle 12, a springloaded shaft 78 is moved inwardly, thereby turning the control switch 76 to an on" position and connecting the male jack 80 with the grounded terminal. When the trigger 14 is released, the spring-loaded shaft 78 moves away from the handle 12, thereby turning the control switch to an off position and disconnecting the male jack 80 from the grounded terminal. The shaft 78 is centered and retained inthe gun handle 12 by the fitting 79.

The switch 76 is secured to the gun handle 12 by the jam nut 82. A cylindrical sleeve member 81, which is integrally formed with the gun handle 12 surrounds the jack 80 and a portion of the switch 76 to shield the jack 80 from any sudden jar which could be caused, for example, by dropping the gun. Also shown in FIG. 1 is a cord 84 containing a single conducting wire and having one end which includes a female jack 85 adapted to engage and connect with the male jack 80. When the female jack 85 and the male jack 80 are engaged, the wire within the cord 84 and the grounded terminal (not shown) are electrically connected. The female jack 85 is retained in engagement with the male jack 80 by the resilient nature of the female jack 85. Although it is specifically shown in FIG. 1, the cord 84'extends from the male jack 80 to a relay switch contained in the powdersupply 75, which, when energized, actuates both the powder supply 75 and the high voltage source 30.

The preferred embodiment further includes a supply unit having a plurality of flexible hoses 70 (a-c) and a plurality of cords 84 (0-0) associated respectively with each of the'hoses (a-c); All of the hoses 70 ((2-0) and the cords 84 (a-c) have one end connected with a powder supply means and the other end adapted for selective engagement with the material passage 18 and the male jack respectively by appropriate connections. In this respect, each of hoses 70 (a-c) includes a fitting 71 (a c) respectively corresponding to the fitting 71 for engagement with the threaded member 72, and a relatively rigid tube 65 (a-c) respectively corresponding to the tube 65 for insertion into the chamber 18. Also, each of the cords 84 a-c) includes a female jack corresponding to the female jack 85 adapted to engage the male jack 80. Each of the tubes 70 (a-c) are held to the corresponding cord 84 (a-c) respectively by a clamp 88 so that corresponding pairs of hoses 70 (a-c) and cords 84 (a-c) will be connected with the gun 10 together.

Each of the pairs of hoses 70 (a-c) and cords 84 (a-c) is associated with a pulverulent material having a different characteristic which can be selectively engaged with the gun 10 when a material with a particular characteristic is desired. For example, the hose 70a, the tube 65 a and the cord 84a are all associated with a material having a certain characteristic and when it is desired to coat this particular material onto the article 13, the tube 65a with the hose 70a attached is inserted into the material passage 18 and the fitting 71a is tightened over the fitting 72. Likewise, the cord 84a is connected with the male jack 80. When a material having a different characteristic is desired to be coated onto the article, the tube 65a, the hose 70a and cord 84a are removed, and the hose, tube and cord associated with that different material are connected with the material passage 18 and the male jack 80 in a similar manner. Although the pulverulent materials with different characteristics commonly would be materials having different colors, the different characteristics could be differences in materials also such as vinyl, polyester, or cellulose-acetate-bu tyrate.

Each of the cords 84 (a-c) shown in FIG. 1 like the cord 84, is electrically connected to a relay switch which, when energized, actuates the high voltage source 30 and that portion of the powder supply 75 with which the cord 84 (a-c) is associated. For example, if the hose 70c and the cord 844 are each associated with certain pulverulent material and each are connected to the gun 10 as above described, depression of the trigger 14 will cause the circuit to be completed between the grounded terminal and the conducting wire within the cord 84a to energize a relay switch, When this relay switch is energized, the high voltage source 30 and that portion of the powder supply 75 associated with the cord 84a and hose 70a is actuated. When the trigger 14 is released, the circuit between the grounded terminal and the wire within the cord 84a is open and the relay switch is deenergized, thereby turning off the power source 30 and the powder supply 75.

When a material having a different characteristic is desired to be coated onto the article 13, the hose 70a and the cord 84a are disengaged from the gun 10, the ionization member 37 taken out and cleaned by compressed air and then replaced, and one of the other hoses 70 (b, c) and cords 84 (b, c) associated with a material having the desired characteristic are connected to the gun 10.

Although the description of the present invention has been quite specific, it is understood by the application that there may be many alternative embodiments of the'present invention which can be constructed without deviating from the spirit of the invention. Consequently, the scope of the present invention should be dictated by the appended claims rather than by the description of the preferred embodiment.

We claim;

1. An electrostatic powder coating apparatus for electrostatically coating the surfaces of articles with pulverulent materials comprising:

a gun body having a longitudinal passage therethrougli, said longitudinal passage having an inlet for receiving pulverulent materials and a discharge for discharging said pulverulent materials from the gun body toward an article to be coated;

an elongated ionization member having a first end disposed within said longitudinal passage and a second end spaced forward from the discharge of said gun, said ionization member further including a probe extending from said first end to said second end of said ionization member, said probe being constructed of an electrically conductive material,

a body member constructed of an electrically non-conductive material surrounding said probe and extending from said first end to a point along said probe such that substantially all of said probe disposed within said passage is surrounded by said body member,

a deflecting member for deflecting pulverulent materials being discharged from said discharge, said deflecting member being constructed of an electrically non-conductive material and disposed near said second end such that said deflecting member is spaced from said body member so that a portion of the probe immediately to the rear of said deflecting member is exposed to pulverulent materials passing through said passage and such that a portion of said probe passes through said deflecting member and extends past an exterior surface of said deflecting member; and means for connecting a high voltage energy source with said probe so as to maintain a high voltage difference between said probe and the article to be coated. I

2. The electrostatic powder coating apparatus of claim I having a sleeve member constructed of electrically non-conductive material which, is slidably mounted to said gun body adjacent to the discharge of said longitudinal passage for axial movement therealong, said sleeve member being movable from a retracted position to a plurality of extended positions in which the front end of said sleeve member is forwardly spaced from the discharge of said passage.

3. The electrostatic powder coating apparatus of claim 2 having means for axially moving said sleeve member and means for retaining said sleeve member in any desired axial position and limiting the axial movement of said sleeve member. a

4. The electrostatic powder coating apparatus of claim 3 wherein said means for retaining said sleeve member in a desired axial position includes a threaded member extending through a portion of said sleeve member and engaging a longitudinal channel on the surface of said gun body.

5. The electrostatic powder coating apparatus of claim 1 having a contact member constructed of an electrically conductive material, said contact member being secured to said body member and electrically connected to said probe.

6. The electrostatic powder coating-apparatus of claim 5 wherein said means for connecting a high voltage energy source with said probe includes an electrically conducting member projecting into said passage and engaging said contact member for electrically connecting the high voltage source with said contact member and for limiting the movement of said ionization member into said passage.

7. The electrostatic powder coating apparatus of claim 1 having a plurality of fins integrally formed with said body member, said fins being circumferentially spaced about the periphery of said body member and extending radially outwardly therefrom for retaining said ionization member within said passage. I

8. The electrostatic powder coating apparatus of claim 7 having a contact member constructed of an electrically conductive material, said contact member being mounted to a portion of said fins and electrically connected to said probe, such that a portion of said contact member is radially spaced from said body member.

9. The electrostatic powder coating apparatus of claim 8 wherein there are four fins constructed of a relatively flexible material for resiliently retaining said ionization member within said passage and wherein said means for connecting a high voltage energy source with said probe includes an electrically conducting member projecting into said passage between an adjacent pair of said fins and engaging said contact member for electrically connecting the high voltage source with said contact member and for limiting the movement of said ionization member into said passage.

10. The electrostatic powder coating apparatus of claim 9 wherein said contact member is a relatively circular ring having an external diameter conforming substantially to the internal diameter of said passage and having an internal diameter substantially greater than the external diameter of said body member such that pulverulent material passage through said passage must pass between said body member and said ring.

11. The electrostatic powder coating apparatus of claim 1 wherein said deflecting member includes a concave surface which is perpendicular to the longitudinal axis of said probe and which is the surface of said deflecting member past which a portion of said probe extends.

12. The electrostatic powder coating apparatus of claim 11 wherein said concave surface joins with a second surface of said deflecting member to form an edge such that all portions of said edge are spaced forwardly from the. discharge of said passage at least asfar as the portion of said probe extending past said concave surface.

13. The electrostatic powder coating apparatus of claim 2 having a contact member constructed of an electrically conductive material, said contact member being connected with said body member and electrically connected to said probe.

14. The electrostatic powder coating apparatus of claim 2 having a plurality of fins integrally formed with said body member, said fins being circumferentially spaced about the periphery of said body member and extending radially outwardly therefrom for retaining said ionization member within said longitudinal passage.

15. The electrostatic powder coating apparatus of claim 2 wherein said deflecting member includes a concave surface which is perpendicular to the longitudinal axis of said probe and which is the surface of said deflecting member past which a portion of said probe extends.

16. The electrostatic powder coating apparatus of claim 13 having a plurality of fins integrally formed with said body member, said fins being circumferentially spaced about the periphery of said body member and extending radially outwardly therefrom for retaining said ionization member within said longitudinal passage.

17. The electrostatic powder coating apparatus of claim 13 wherein said deflecting member includes a concave surface which is perpendicular to the longitudinal axis of said probe and which is the surface of said deflecting member past which a portion of said probe extends.

18. The electrostatic powder coating apparatus of claim 16 wherein said deflecting member includes a concave surface which is perpendicular to the longitudinal axis of said probe and which is the surface of said deflecting memberpast which a portion of said probe extends.

19. The electrostatic powder coating apparatus of claim 18 wherein said contact member is mounted to a portion of said fins and is adapted for engaging a conducting member projecting into said passage for electrically connecting the high voltage source with said probe and for limiting the movement of said ionization member into said passage, and wherein said concave surface joins with a second surface of said deflecting member to form an edge such that all portions of said edge are spaced forwardly from the discharge of said passage at least as far as the portion of said probe extending past said concave surface.

20. A charging and deflecting unit for use in an electrostatic powder coating apparatus for electrostatically coating the surfaces of articles with pulverulent materials, said apparatus having a passage through which dispersed pulverulent materials are conveyed and a discharge end of said passage through which said pulverulent materials are discharged, said charging and deflecting unit comprising:

an electrically non-conductive deflecting member around which pulverulent material must be deflected upon leaving the discharge end of said gun, said deflecting member being spaced forwardly from the discharge end of said passage and oriented centrally along the extended longitudinal axis of said passage;

a central charging electrode portion positioned immediately to the rear of said deflecting member and exposed to the pulverulent materials being discharged from said passage;

a forward charging electrode portion positioned immediately forward of said deflecting member;

means connecting said charging electrode portion and said forward charging electrode portion with a high voltage power source for maintaining both of said electrode portions at an electrical potential substantially different from that of said article to be coated; and

a sleeve member constructed of electrically non-conductive material which is slidably mounted to said gun body adjacent to the discharge end of said passage for axial movement therealong, said sleeve member being movable from a retracted position to a plurality of extended positions in which the front end of said member is forwardly spaced from the discharge end of said passage for thereby varying the pattern of said pulverulent materials being discharged from said passage.

21. The charging and deflecting unit of claim 20 wherein said central charging electrode portion is spaced forward of the discharge end of said passage.

22. The charging and deflecting unit of claim 20 wherein said deflecting member includes a concave surface substantially perpendicular to the extended longitudinal axis of said passage and wherein said concave surface joins with a second surface of said deflecting member to form an edge such that all portions of said edge are spaced forwardly from the discharge end of said passage at least as far as said forward charging electrode portion.

23. The charging and deflecting unit of claim 20 having a body member rigidly connected with said central charging electrode portion and said deflecting member, said body member extending into said passage and being resiliently retained therein for supporting said deflecting member.

24. The charging and deflecting unit of claim 23 wherein a portion of said central charging electrode portion extends through said body member. 

1. An electrostatic powder coating apparatus for electrostatically coating the surfaces of articles with pulverulent materials comprising: a gun body having a longitudinal passage therethrough, said longitudinal passage having an inlet for receiving pulverulent materials and a discharge for discharging said pulverulent materials from the gun body toward an article to be coated; an elongated ionization member having a first end disposed within said longitudinal passage and a second end spaced forward from the discharge of said gun, said ionization member further including a probe extending from said first end to said second end of said ionization member, said probe being constructed of an electrically conductive material, a body member constructed of an electrically non-conductive material surrounding said probe and extending from said first end to a point along said probe such that substantially all of said probe disposed within said passage is surrounded by said body member, a deflecting member for deflecting pulverulent materials being discharged from said discharge, said deflecting member being constructed of an electrically non-conductive material and disposed near said second end such that said deflecting member is spaced from said body member so that a portion of the probe immediately to the rear of said deflecting member is exposed to pulverulent materials passing through said passage and such that a portion of said probe passes through said deflecting member and extends past an exterior surface of said deflecting member; and means for connecting a high voltage energy source with said probe so as to maintain a high voltage difference between said probe and the article to be coated.
 2. The electrostatic powder coating apparatus of claim 1 having a sleeve member construCted of electrically non-conductive material which is slidably mounted to said gun body adjacent to the discharge of said longitudinal passage for axial movement therealong, said sleeve member being movable from a retracted position to a plurality of extended positions in which the front end of said sleeve member is forwardly spaced from the discharge of said passage.
 3. The electrostatic powder coating apparatus of claim 2 having means for axially moving said sleeve member and means for retaining said sleeve member in any desired axial position and limiting the axial movement of said sleeve member.
 4. The electrostatic powder coating apparatus of claim 3 wherein said means for retaining said sleeve member in a desired axial position includes a threaded member extending through a portion of said sleeve member and engaging a longitudinal channel on the surface of said gun body.
 5. The electrostatic powder coating apparatus of claim 1 having a contact member constructed of an electrically conductive material, said contact member being secured to said body member and electrically connected to said probe.
 6. The electrostatic powder coating apparatus of claim 5 wherein said means for connecting a high voltage energy source with said probe includes an electrically conducting member projecting into said passage and engaging said contact member for electrically connecting the high voltage source with said contact member and for limiting the movement of said ionization member into said passage.
 7. The electrostatic powder coating apparatus of claim 1 having a plurality of fins integrally formed with said body member, said fins being circumferentially spaced about the periphery of said body member and extending radially outwardly therefrom for retaining said ionization member within said passage.
 8. The electrostatic powder coating apparatus of claim 7 having a contact member constructed of an electrically conductive material, said contact member being mounted to a portion of said fins and electrically connected to said probe, such that a portion of said contact member is radially spaced from said body member.
 9. The electrostatic powder coating apparatus of claim 8 wherein there are four fins constructed of a relatively flexible material for resiliently retaining said ionization member within said passage and wherein said means for connecting a high voltage energy source with said probe includes an electrically conducting member projecting into said passage between an adjacent pair of said fins and engaging said contact member for electrically connecting the high voltage source with said contact member and for limiting the movement of said ionization member into said passage.
 10. The electrostatic powder coating apparatus of claim 9 wherein said contact member is a relatively circular ring having an external diameter conforming substantially to the internal diameter of said passage and having an internal diameter substantially greater than the external diameter of said body member such that pulverulent material passage through said passage must pass between said body member and said ring.
 11. The electrostatic powder coating apparatus of claim 1 wherein said deflecting member includes a concave surface which is perpendicular to the longitudinal axis of said probe and which is the surface of said deflecting member past which a portion of said probe extends.
 12. The electrostatic powder coating apparatus of claim 11 wherein said concave surface joins with a second surface of said deflecting member to form an edge such that all portions of said edge are spaced forwardly from the discharge of said passage at least as far as the portion of said probe extending past said concave surface.
 13. The electrostatic powder coating apparatus of claim 2 having a contact member constructed of an electrically conductive material, said contact member being connected with said body member and electrically connected to said probe.
 14. The electrostatic powder coating apparaTus of claim 2 having a plurality of fins integrally formed with said body member, said fins being circumferentially spaced about the periphery of said body member and extending radially outwardly therefrom for retaining said ionization member within said longitudinal passage.
 15. The electrostatic powder coating apparatus of claim 2 wherein said deflecting member includes a concave surface which is perpendicular to the longitudinal axis of said probe and which is the surface of said deflecting member past which a portion of said probe extends.
 16. The electrostatic powder coating apparatus of claim 13 having a plurality of fins integrally formed with said body member, said fins being circumferentially spaced about the periphery of said body member and extending radially outwardly therefrom for retaining said ionization member within said longitudinal passage.
 17. The electrostatic powder coating apparatus of claim 13 wherein said deflecting member includes a concave surface which is perpendicular to the longitudinal axis of said probe and which is the surface of said deflecting member past which a portion of said probe extends.
 18. The electrostatic powder coating apparatus of claim 16 wherein said deflecting member includes a concave surface which is perpendicular to the longitudinal axis of said probe and which is the surface of said deflecting member past which a portion of said probe extends.
 19. The electrostatic powder coating apparatus of claim 18 wherein said contact member is mounted to a portion of said fins and is adapted for engaging a conducting member projecting into said passage for electrically connecting the high voltage source with said probe and for limiting the movement of said ionization member into said passage, and wherein said concave surface joins with a second surface of said deflecting member to form an edge such that all portions of said edge are spaced forwardly from the discharge of said passage at least as far as the portion of said probe extending past said concave surface.
 20. A charging and deflecting unit for use in an electrostatic powder coating apparatus for electrostatically coating the surfaces of articles with pulverulent materials, said apparatus having a passage through which dispersed pulverulent materials are conveyed and a discharge end of said passage through which said pulverulent materials are discharged, said charging and deflecting unit comprising: an electrically non-conductive deflecting member around which pulverulent material must be deflected upon leaving the discharge end of said gun, said deflecting member being spaced forwardly from the discharge end of said passage and oriented centrally along the extended longitudinal axis of said passage; a central charging electrode portion positioned immediately to the rear of said deflecting member and exposed to the pulverulent materials being discharged from said passage; a forward charging electrode portion positioned immediately forward of said deflecting member; means connecting said charging electrode portion and said forward charging electrode portion with a high voltage power source for maintaining both of said electrode portions at an electrical potential substantially different from that of said article to be coated; and a sleeve member constructed of electrically non-conductive material which is slidably mounted to said gun body adjacent to the discharge end of said passage for axial movement therealong, said sleeve member being movable from a retracted position to a plurality of extended positions in which the front end of said member is forwardly spaced from the discharge end of said passage for thereby varying the pattern of said pulverulent materials being discharged from said passage.
 21. The charging and deflecting unit of claim 20 wherein said central charging electrode portion is spaced forward of the discharge end of said passage.
 22. The charging and deflecting unit of claim 20 wherein said deflecting member includes a concave surface substantially perpendicular to the extended longitudinal axis of said passage and wherein said concave surface joins with a second surface of said deflecting member to form an edge such that all portions of said edge are spaced forwardly from the discharge end of said passage at least as far as said forward charging electrode portion.
 23. The charging and deflecting unit of claim 20 having a body member rigidly connected with said central charging electrode portion and said deflecting member, said body member extending into said passage and being resiliently retained therein for supporting said deflecting member.
 24. The charging and deflecting unit of claim 23 wherein a portion of said central charging electrode portion extends through said body member. 